US Powder Coatings Market Outlook and Forecast (2025-2035)
The US powder coatings market is experiencing significant growth due to increasing demand for eco-friendly, durable coating solutions across major industries including automotive, consumer goods, and architecture. Powder coatings are solvent-free, offering environmental advantages, cost efficiencies, and improved performance over traditional liquid coatings. Rapid advances in application technologies and expanding usage across new segments are expected to bolster market expansion through 2035.
Latest Market Dynamics
Key Drivers
Increasing environmental regulations are driving stronger adoption of powder coatings as they contain no solvents or VOCs. Automotive manufacturers such as Ford have expanded the use of powder coatings for both performance and compliance, making this a primary driver in 2025.
Surge in demand for durable, long-lasting finishes in appliances and consumer goods is propelling market growth. Companies like Whirlpool have upgraded their manufacturing lines to utilize advanced powder coatings for high-wear components.
Key Trends
Shift toward sustainable and green coatings fuels innovation in bio-based powder formulations, led by players such as PPG Industries who have introduced low-emission product lines in 2024.
Digitalization and automation in powder coating application processes, with Akzo Nobel N.V. and Sherwin-Williams investing in AI-controlled spray booths to improve coating efficiency and product consistency.
Key Opportunities
Expansion into architectural applications due to growing construction activities in commercial and residential sectors, as seen by increasing powder coatings supply contracts secured by Axalta Coating Systems in 2024.
Growth in e-commerce and online distribution of powder coatings, allowing smaller customers and OEMs easier access, highlighted by BASF SE’s launch of a dedicated B2B e-commerce portal for coatings in mid-2024.
Key Challenges
Complexity of formulation and production to meet strict performance standards across varied applications remains a challenge, especially for smaller producers like Sun Polymers.
Rising raw material costs and supply chain disruptions, as reported by Jotun in Q3 2024, impacting profit margins and pricing flexibility across the value chain.
Key Restraints
High initial investment in specialized application equipment limits adoption among small to mid-sized organizations, a challenge highlighted by market feedback received by IFS Coatings.
Technical limitations in achieving ultra-thin or specialty finishes compared to wet coatings, which restricts market potential in certain niche segments, as faced by American Powder Coatings.
In 2025, thermoset powder coatings lead the US market owing to their superior chemical and weather resistance, making them suitable for a wide range of applications, especially in automotive and architectural sectors. Thermoplastic types are gaining ground due to increased use in appliances and furniture, while specialized sub-types such as epoxy and polyester also contribute to market diversity. The dominance of thermoset types highlights industry preference for robust performance over cost alone.
US Powder Coatings Market Share (%) by Applications, 2025
The automotive sector remains the largest consumer of powder coatings in the US with a 34% market share, driven by the need for corrosion resistance and durability. Consumer goods, particularly appliances, account for 27%, reflecting the rising trend of powder coatings in white goods for superior finish and color stability. Architectural applications occupy the third spot, supported by green building codes and sustainability initiatives. This diverse application portfolio underlines the versatility and broad appeal of powder coatings.
US Powder Coatings Market Revenue (USD Million), 2020-2035
Market revenue has shown steady growth from 2020 to 2025, with a projected acceleration through 2035. Estimated at $1,620 million in 2021, revenue surpassed $2,000 million in 2025 and is forecasted to exceed $3,750 million by 2035. This upward trajectory reflects robust demand across industries, adoption of advanced coating technologies, and ongoing expansions by leading producers.
US Powder Coatings Market YoY Growth (%), 2020-2035
The year-on-year growth for the US powder coatings market maintained a healthy average of around 5.8% during 2020-2025, with slight increases projected as new applications and green initiatives boost demand. Growth is expected to peak at 6.4% between 2028 and 2030, before stabilizing at 5% by 2035 as the market matures and reaches higher penetration rates.
US Powder Coatings Market Share (%) by Region, 2025
The Midwest region dominates the US powder coatings market in 2025 with a 38% share, attributed to its concentration of automotive and manufacturing industries. The South follows at 32%, benefiting from construction growth and appliance manufacturing hubs. The West and Northeast regions together account for 30% of demand, led by architectural and high-tech manufacturing activity. This regional distribution reflects the alignment of demand hotspots with key industrial clusters.
Market leadership in the US powder coatings segment is firmly held by PPG Industries (23%) and Sherwin-Williams (19%), both of which have extensive nationwide distribution and strong R&D capabilities. Akzo Nobel N.V. holds 13%, primarily from its architectural coatings business. The remainder of the market is fragmented, with key players like Axalta and BASF SE each holding below 10%. This competitive landscape encourages innovation and continuous quality improvement.
Original Equipment Manufacturers (OEM) account for the bulk of powder coatings consumption at 41%, reflecting large-volume, high-consistency requirements. Distributors and online channels combined cover 36%, as demand from mid-sized and small businesses grows. Direct retail buyers make up the remaining 23%, indicating that professional and niche users still play a significant role in the US market. Buyer dynamics are shifting toward greater transparency and online access.
Study Coverage
Metrics
Details
Years
2020-2035
Base Year
2025
Market Size
Revenue (USD Million)
Regions
Midwest, South, West, Northeast
Segments
By Type (Thermoset, Thermoplastic, Epoxy, Polyester, Acrylic, Polyurethane) and By Application (Automotive, Consumer Goods, Architectural, Furniture, General Industries, Appliances)
June 2024: PPG Industries introduced its new generation eco-friendly powder coatings with enhanced antimicrobial features, targeting the healthcare sector.
July 2024: Akzo Nobel N.V. launched a sustainable architectural powder coating series in partnership with a major US green building developer.
August 2024: Sherwin-Williams announced the expansion of its Texas powder coatings plant to meet growing automotive and appliance sector demand.
September 2024: BASF SE rolled out an e-commerce platform for US industrial powder coatings, streamlining procurement for OEMs and mid-sized buyers.
October 2024: Axalta Coating Systems signed a high-value supply agreement with a leading US consumer electronics brand for innovative powder finish solutions.
Frequently Asked Questions
About the Author
Ankita R
Lead Industry Analyst
Ankita R is a Lead Industry Analyst specializing in market research, industry analysis, and business consulting across Chemical & Material. Ankita R brings a commercially grounded perspective to sectors shaped by changing demand, innovation, and competitive dynamics, helping turn complex market trends into clear strategic insights for business decision-makers. With 10+ years of experience across research, analytics, and strategic advisory roles, Ankita R has helped organizations translate data into actionable growth strategies.
Chemical & MaterialMarket ResearchIndustry AnalysisStrategic Consulting
Key Questions Answered
»What is the market size and growth rate of the global and regional market by various segments?
»What is the market size and growth rate of the market for selective countries?
»Which region or sub-segment is expected to drive the market in the forecast period?
»What factors are estimated to drive and restrain the market growth?
»What are the key technological and market trends shaping the market?
»What are the key opportunities in the market?
»What are the key companies operating in the market?
»Which company accounted for the highest market share?
